Note: Descriptions are shown in the official language in which they were submitted.
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Method and device for producing direct reduced metal
The present invention relates to a method and a device for producing direct
reduced
metal, and in particular direct reduced iron (also known as sponge iron). In
particular, the
present invention relates to the direct reduction of metal ore under a
controlled hydrogen
atmosphere to produce such direct reduced metal.
The production of direct reduced metal using hydrogen as a reducing agent is
well-known
as such. For instance, in 5E7406174-8 and 5E7406175-5 methods are described in
which a
charge of metal ore is subjected to a hydrogen atmosphere flowing past the
charge, which
as a result is reduced to form direct reduced metal.
The present invention is particularly applicable in the case of batchwise
charging and
treatment of the material to be reduced.
There are several problems with the prior art, including efficiency regarding
thermal losses
as well as hydrogen gas usage. There is also a control problem, since it is
necessary to
measure when the reduction process has been finalized.
The present invention solves the above described problems.
Hence, the invention relates to a method for producing direct reduced metal
material,
comprising the steps: a) charging metal material to be reduced into a furnace
space; b)
evacuating an existing atmosphere from the furnace space so as to achieve an
underpres-
sure inside the furnace space; c) providing, in a main heating step, heat and
hydrogen gas
to the furnace space, so that heated hydrogen gas heats the charged metal
material to a
temperature high enough so that metal oxides present in the metal material are
reduced,
in turn causing water vapour to be formed; and d) condensing and collecting
the water
vapour formed in step c in a condenser below the charged metal material; which
method
is characterised in that said hydrogen gas in step c is provided without
recirculation of the
hydrogen gas, and in that the method further comprises the subsequently
performed step
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of removing the reduced metal material from the furnace space (120), and
storing and/or
transporting the reduced metal material under an inert atmosphere.
In the following, the invention will be described in detail, with reference to
exemplifying
embodiments of the invention and to the enclosed drawings, wherein:
Figure la is a cross-section of a simplified furnace for use in a system
according to the
present invention, during a first operation state;
Figure lb is a cross-section of the simplified furnace of Figure la, during a
second opera-
/0 tion state;
Figure 2 is a schematic overview of a system according to the present
invention;
Figure 3 is a flowchart of a method according to the present invention; and
Figure 4 is a chart showing a possible relation between H2 pressure and
temperature in a
heated furnace space according to the present invention.
Figures la and lb share the same reference numerals for same parts.
Hence, figures la and lb illustrate a furnace 100 for producing direct reduced
metal
material. In Figure 2, two such furnaces 210, 220 are illustrated. The
furnaces 210, 220
may be identical to furnace 100, or differ in details. However, it is
understood that every-
thing which is said herein regarding the furnace 100 is equally applicable to
furnaces 210
and/or 220, and vice versa.
Furthermore, it is understood that everything which is said herein regarding
the present
method is equally applicable to the present system 200 and/or furnace 100;
210, 220, and
vice versa.
The furnace 100 as such has many similarities with the furnaces described in
5E7406174-8
and 5E7406175-5, and reference is made to these documents regarding possible
design
details. However, an important difference between these furnaces and the
present
furnace 100 is that the present furnace 100 is not arranged to be operated in
a way where
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hydrogen gas is recirculated through the furnace 100 and back to a collecting
container
arranged outside of the furnace 100, and in particular not in a way where
hydrogen gas is
recirculated out from the furnace 100 (or heated furnace space 120) and then
back into
the furnace 100 (or heated furnace space 120) during one and the same batch
processing
of charged material to be reduced.
Instead, and as will be apparent from the below description, the furnace 100
is arranged
for batch-wise reducing operation of one charge of material at a time, and to
operate
during such an individual batch processing as a closed system, in the sense
that hydrogen
gas is supplied to the furnace 100 but not removed therefrom during the batch-
wise
reducing step.
In other words, the amount of hydrogen gas present inside the furnace 100
always in-
creases during the reduction process. After reduction has been completed, the
hydrogen
gas is of course evacuated from within the furnace 100, but there is no
recirculation of
hydrogen gas during the reduction step.
Hence, the furnace 100 is part of a closed system comprising a heated furnace
space 120
which arranged to be pressurized, such as to at least 5 bars, or at least 6
bars, or at least 8
bars, or even at least 10 bars. An upper part 110 of the furnace 100 has a
bell-shape. It can
be opened for charging of material to be processed, and can be closed in a gas-
tight
manner using fastening means 111. The furnace space 120 is encapsulated with
refractory
material, such as brick material 130.
The furnace space 120 is arranged to be heated using one or several heating
elements
121. Preferably, the heating elements 121 are electric heating elements.
However, radia-
tor combustion tubes or similar fuel-heated elements can be used as well. The
heating
elements 121 do not, however, produce any combustion gases that interact
directly
chemically with the furnace space 120, which must be kept chemically
controlled for the
present purposes. It is preferred that the only gaseous matter provided into
the furnace
space during the below-described main heating step is hydrogen gas.
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The heating elements 121 may preferably be made of a heat-resistant metal
material,
such as a molybdenum alloy.
Additional heating elements may also be arranged in the heated furnace space
120. For
instance, heating elements similar to elements 121 may be provided at the side
walls of
the furnace space 120, such as at a height corresponding to the charged
material or at
least to the container 140. Such heating elements may aid heating not only the
gas, but
also the charged material via heat radiation.
The furnace 100 also comprises a lower part 150, forming a sealed container
together with
the upper part 110 when the furnace is closed using fastening means 111.
A container 140 for material to be processed (reduced) is present in the lower
part 150 of
the furnace 100. The container 140 may be supported on a refractory floor of
the furnace
space 120 in a way allowing gas to pass beneath the container 140, such as
along open or
closed channels 172 formed in said floor, said channels 172 passing from an
inlet 171 for
hydrogen gas, such as from a central part of the furnace space 120 at said
furnace floor,
radially outward to a radial periphery of the furnace space 120 and thereafter
upwards to
an upper part of the furnace space 120. See flow arrows indicated in Figure la
for these
flows during the below-described initial and main heating steps.
The container 140 is preferably of an open constitution, meaning that gas can
pass freely
through at least a bottom/floor of the container 140. This may be
accomplished, for
instance, by forming holes through the bottom of the container 140.
The material to be processed comprises a metal oxide, preferably an iron oxide
such as
Fe2O3 and/or Fe304. The material may be granular, such as in the form of
pellets or balls.
One suitable material to be charged for batch reduction is rolled iron ore
balls, that have
been rolled in water to a ball diameter of about 1-1.5 cm. If such iron ore
additionally
contains oxides that evaporate at temperatures below the final temperature of
the
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charged material in the present method, such oxides may be condensed in the
condenser
160 and easily collected in powder form. Such oxides may comprise metal oxides
such as
Zn and Pb oxides.
5 .. Advantageously, the furnace space 120 is not charged with very large
amounts of material
to be reduced. Each furnace 100 is preferably charged with at the most 50
tonnes, such as
at the most 25 tonnes, such as between 5 and 10 tonnes, in each batch. This
charge may
be held in one single container 150 inside the furnace space 120. Depending on
through-
put requirements, several furnaces 100 may be used in parallel, and the
residual heat
from a batch in one furnace 220 can then be used to preheat another furnace
210 (see
Figure 2 and below).
This provides a system 200 which is suitable for installation and use directly
at the mining
site, requiring no expensive transport of the ore before reduction. Instead,
direct reduced
metal material can be produced on-site, packaged under a protecting atmosphere
and
transported to a different site for further processing.
Hence, in the case of water-rolled iron ore balls, it is foreseen that the
furnace 100 may be
installed in connection to the iron ore ball production system, so that
charging of the
metal material into the furnace 100 in the container 140 can take place in a
fully automat-
ed manner, where containers 140 are automatically circulated from the iron ore
ball
production system to the system 100 and back, being filled with iron ore balls
to be
reduced; inserted into the furnace space 120; subjected to the reducing
hydrogen/heat
processing described herein; removed from the furnace space 120 and emptied;
taken
back to the iron ore ball production system; refilled; and so forth. More
containers 140
may be used than furnaces 100, so that in each batch switch a reduced charge
in a particu-
lar container is immediately replaced in the furnace 100 with a different
container carry-
ing material not yet reduced. Such a larger system, such as at a mining site,
may be im-
plemented to be completely automated, and also to be very flexible in terms of
through-
put, using several smaller furnaces 100 rather than one very large furnace.
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Below the container 140, the furnace 100 comprises a gas-gas type heat
exchanger 160,
which may advantageously be a tube heat exchanger such as is known per se. The
heat
exchanger 160 is preferably a counter-flow type heat exchanger. To the heat
exchanger
160, below the heat exchanger 160, is connected a closed trough 161 for
collecting and
accommodating condensed water from the heat exchanger 160. The trough 161 is
also
constructed to withstand the operating pressures of the furnace space 120 in a
gas-tight
manner.
The heat exchanger 160 is connected to the furnace space 120, preferably so
that
cool/cooled gases arriving to the furnace space 120 pass the heat exchanger
160 along
externally/peripherally provided heat exchanger tubes and further through said
channels
172 up to the heating element 121. Then, heated gases passing out from the
furnace
space 120, after passing and heating the charged material (see below), pass
the heat
exchanger 160 through internally/centrally provided heat exchanger tubes,
thereby
heating said cool/cooled gases. The outgoing gases hence heat the incoming
gases both by
thermal transfer due to the temperature difference between the two, as well as
by the
condensing heat of condensing water vapour contained in the outgoing gases
effectively
heating the incoming gases.
The formed condensed water from the outgoing gases is collected in the trough
161.
The furnace 100 may comprise a set of temperature and/or pressure sensors in
the trough
161 (122); at the bottom of the furnace space 120, such as below the container
140 (123)
and/or at the top of the furnace space 120 (124). These sensors may be used by
control
unit 201 to control the reduction process, as will be described below.
171 denotes an entry conduit for heating/cooling hydrogen gas. 173 denotes an
exit
conduit for used cooling hydrogen gas.
Between the trough 161 and the entry conduit 171 there may be an overpressure
equili-
bration channel 162, with a valve 163. In case an overpressure builds up in
the trough 161,
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due to large amounts of water flowing into the trough 161, such an
overpressure may
then be released to the entry conduit 171. The valve 163 may be a simple
overpressure
valve, arranged to be open when the pressure in trough 161 is higher than the
pressure in
the conduit 171. Alternatively, the valve may be operated by control device
201 (below)
based on a measurement from pressure sensor 122.
Condensed water may be led from the condenser/heat exchanger 160 may be led
down
into the trough via a spout 164 or similar, debouching at a bottom of the
trough 161, such
as at a local low point 165 of the trough, preferably so that an orifice of
said spout 164 is
arranged fully below a main bottom 166 of the trough 161 such as is
illustrated in Figure
la. This will decrease liquid water turbulence in the trough 161, providing
more controlla-
ble operation conditions.
The trough 161 is advantageously dimensioned to be able to receive and
accommodate all
water formed during the reduction of the charged material. The size of trough
161 can
hence be adapted for the type and volume of one batch of reduced material. For
instance,
when fully reducing 1000 kg of Fe304, 310 liters of water is formed, and when
fully reduc-
ing 1000 kg of Fe2O3, 338 liters of water is formed.
In Figure 2, a system 200 is illustrated in which a furnace of the type
illustrated in Figures
la and lb may be put to use. In particular, one or both of furnaces 210 and
220 may be of
the type illustrated in Figures la and lb, or at least according to the
present claim 1.
230 denotes a gas-gas type heat exchanger. 240 denotes a gas-water type heat
exchanger.
250 denotes a fan. 260 denotes a vacuum pump. 270 denotes a compressor. 280
denotes
a container for used hydrogen gas. 290 denotes a container for fresh/unused
hydrogen
gas. V1-V14 denote valves.
201 denotes a control device, which is connected to sensors 122, 123, 124 and
valves V1-
V14, and which is generally arranged to control the processes described
herein. The
control device 201 may also be connected to a user control device, such a
graphical user
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interface presented by a computer (not shown) to a user of the system 200 for
supervision
and further control.
Figure 3 illustrates a method according to the present invention, which method
uses a
system 100 of the type generally illustrated in Figure 3 and in particular a
furnace 100 of
the type generally illustrated in Figures la and lb. In particular, the method
is for produc-
ing direct reduced metal material using hydrogen gas as the reducing agent.
After such direct reduction, the metal material may form sponge metal. In
particular, the
.. metal material may be iron oxide material, and the resulting product after
the direct
reduction may then be sponge iron. Such sponge iron may then be used, in
subsequent
method steps, to produce steel and so forth.
In a first step, the method starts.
In a subsequent step, the metal material to be reduced is charged into the
furnace space
120. This charging may take place by a loaded container 140 being placed into
the furnace
space 120 in the orientation illustrated in Figures la and lb, and the furnace
space 120
may then be closed and sealed in a gas-tight manner using fastening means 111.
In a subsequent step, an existing atmosphere is evacuated from the furnace
space 120, so
that an underpressure is achieved inside the furnace space 120 as compared to
atmos-
pheric pressure. This may take place by valves 1-8, 11 and 13-14 being closed
and valves 9-
10 and 12 being open, and the vacuum pump sucking out and hence evacuating the
contained atmosphere inside the furnace space 120 via the conduit passing via
240 and
250. Valve 9 may then be open to allow such evacuated gases to flow out into
the sur-
rounding atmosphere, in case the furnace space 120 is filled with air. If the
furnace space
120 is filled with used hydrogen gas, this is instead evacuated to the
container 280.
In this example, the furnace atmosphere is evacuated via conduit 173, even if
it is realized
that any other suitable exit conduit arranged in the furnace 100 may be used.
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In this evacuation step, as well as in other steps as described below, the
control device
201 may be used to control the pressure in the furnace space 120, such as
based upon
readings from pressure sensors 122, 123 and/or 124.
The emptying may proceed until a pressure of at the most 0.5 bar, preferably
at the most
0.3 bar, is achieved in the furnace space 120.
In a subsequent initial heating step, heat and hydrogen gas is provided to the
furnace
space 120. The hydrogen gas may be supplied from the containers 280 and/or
290. Since
the furnace 100 is closed, as mentioned above, substantially none of the
provided hydro-
gen gas will escape during the process. In other words, the hydrogen gas
losses (apart
from hydrogen consumed in the reduction reaction) will be very low or even non-
existent.
Instead, only the hydrogen consumed chemically in the reduction reaction
during the
reduction process will be used. Further, the only hydrogen gas which is
required during
the reduction process is the necessary amount to uphold the necessary pressure
and
chemical equilibrium between hydrogen gas and water vapour during the
reduction
process.
As mentioned above, the container 290 holds fresh (unused) hydrogen gas, while
contain-
er 280 holds hydrogen gas that has already been used in one or several
reduction steps
and has since been collected in the system 200. The first time the reduction
process is
performed, only fresh hydrogen gas is used, provided from container 290.
During subse-
quent reduction processes, reused hydrogen gas, from container 280, is used,
which is
topped up by fresh hydrogen gas from container 290 according to need.
During an optional initial phase of the initial heating step, which initial
phase is one of
hydrogen gas introduction, performed without any heat provision up to a
furnace space
120 pressure of about 1 bar, valves 2, 4-9, 11 and 13-14 are closed, while
valves 10 and 12
are open. Depending on if fresh or reused hydrogen gas is to be used, valve V1
and/or V3
is open.
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As the pressure inside the furnace space 120 reaches, or comes close to,
atmospheric
pressure (about 1 bar), the heating element 121 is switched on. Preferably, it
is the
heating element 121 which provides the said heat to the furnace space 120, by
heating
5 the supplied hydrogen gas, which in turn heats the material in the
container 140. Prefera-
bly, the heating element 121 is arranged at a location past which the hydrogen
gas being
provided to the furnace space 120 flows, so that the heating element 121 will
be substan-
tially submerged in (completely or substantially completely surrounded by)
newly provid-
ed hydrogen gas during the reducing process. In other words, the heat may
advantageous-
io ly be provided directly to the hydrogen gas which is concurrently
provided to the furnace
space 120. In Figure la and lb, the preferred case in which the heating
element 121 is
arranged in a top part of the furnace space 120 is shown.
However, the present inventor foresee that the heat may be provided in other
ways to the
is furnace space 120, such as directly to the gas mixture inside the
furnace space 120 at a
location distant from where the provided hydrogen gas enters the furnace space
120. In
other examples, the heat may be provided to the provided hydrogen gas as a
location
externally to the furnace space 120, before the thus heated hydrogen gas is
allowed to
enter the furnace space 120.
During the rest of the said initial heating step, valves 5 and 7-14 are
closed, while valves 1-
4 and 6 are controlled by the control device, together with the compressor
270, to achieve
a controlled provision of reused and/or fresh hydrogen gas as described in the
following.
.. Hence, during this initial heating step, the control device 201 is arranged
to control the
heat and hydrogen provision means 121, 280, 290 to provide heat and hydrogen
gas to
the furnace space 120 in a way so that heated hydrogen gas heats the charged
metal
material to a temperature above the boiling temperature of water contained in
the metal
material. As a result, said contained water evaporates.
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Throughout the initial heating step and the main heating step (see below),
hydrogen gas is
supplied slowly under the control of the control device 201. As a result,
there will be a
continuously present, relatively slow but steady, flow of hydrogen gas,
vertically down-
wards, through the charged material. In general, the control device is
arranged to contin-
uously add hydrogen gas so as to maintain a desired increasing (such as
monotonically
increasing) pressure curve inside the furnace space 120, and in particular to
counteract
the decreased pressure at the lower parts of the furnace space 120 (and in the
lower parts
of the heat exchanger 160) resulting from the constant condensation of water
vapour in
the heat exchanger 160 (see below). The total energy consumption depends on
the
io efficiency of the heat exchanger 160, and in particular its ability to
transfer thermal energy
to the incoming hydrogen gas from both the hot gas flowing through the heat
exchanger
160 and the condensation heat of the condensing water vapour. In the
exemplifying case
of Fe2O3, the theoretical energy needed to heat the oxide, thermally
compensate for the
endothermic reaction and reduce the oxide is about 250 kWh per 1000 kg of
Fe2O3. For
Fe304, the corresponding number is about 260 kWh per 1000 kg of Fe304.
An important aspect of the present invention is that there is no recirculation
of hydrogen
gas during the reduction process. This has been discussed on a general level
above, but in
the example shown in Figure la this means that the hydrogen gas is supplied,
such as via
compressor 270, through entry conduit 171 into the top part of the furnace
space 121,
where it is heated by the heating element 121 and then slowly passes
downwards, past
the metal material to be reduced in the container 140, further down through
the heat
exchanger 130 and into the trough 161. However, there are no available exit
holes from
the furnace space 120, and in particular not from the trough 161. The conduit
173 is
closed, for instance by the valves V10, V12, V13, V14 being closed. Hence, the
supplied
hydrogen gas will be partly consumed in the reduction process, and partly
result in an
increased gas pressure in the furnace space 120. This process then goes on
until a full or
desired reduction has occurred of the metal material, as will be detailed
below.
Hence, the heated hydrogen gas present in the furnace space 120 above the
charged
material in the container 140 will, via the slow supply of hydrogen gas
forming a slowly
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moving downwards gas stream, be brought down to the charged material. There,
it will
form a gas mixture with water vapour from the charged material (see below).
The resulting hot gas mixture will form a gas stream down into and through the
heat
exchanger 160. In the heat exchanger 160, there will then be a heat exchange
of heat
from the hot gas arriving from the furnace space 120 to the cold newly
provided hydrogen
gas arriving from conduit 171, whereby the latter will be preheated by the
former. In
other words, hydrogen gas to be provided in the initial and main heating steps
is preheat-
ed in the heat exchanger 160.
Due to the cooling of the hot gas flow, water vapour contained in the cooled
gas will
condense. This condensation results in liquid water, which is collected in the
trough 161,
but also in condensation heat. It is preferred that the heat exchanger 160 is
further
arranged to transfer such condensation thermal energy from the condensed water
to the
.. cold hydrogen gas to be provided into the furnace space 120.
The condensation of the contained water vapour will also decrease the pressure
of the hot
gas flowing downwards from the furnace space 120, providing space for more hot
gas to
pass downwards through the heat exchanger 160.
Due to the slow supply of additional heated hydrogen gas, and to the
relatively high
thermal conductivity of hydrogen gas, the charged material will relatively
quickly, such as
within 10 minutes or less, reach the boiling point of liquid water contained
in the charged
material, which should by then be slightly above 100 C. As a result, this
contained liquid
water will evaporate, forming water vapour mixing with the hot hydrogen gas.
The condensation of the water vapour in the heat exchanger 160 will decrease
the partial
gas pressure for the water vapour at the lower end of the structure, making
the water
vapour generated in the charged material on average flow downwards. Adding to
this
effect, water vapour also a substantially lower density than the hydrogen gas
with which it
mixes.
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This way, the water contents of the charged material in the container 140 will
gradually
evaporate, flow downwards through the heat exchanger 160, cool down and
condense
therein and to up in liquid state in the trough 161.
It is preferred that the cold hydrogen gas supplied to the heat exchanger 160
is room
tempered or has a temperature which is slightly less than room temperature.
It is realized that this initial heating step, in which the charged material
is hence dried
from any contained liquid water, is a preferred step in the present method. In
particular,
this makes it easy to produce and provide the charged material as a granular
material,
such as in the form of rolled balls of material, without having to introduce
an expensive
and complicating drying step prior to charging of the material into the
furnace space 120.
However, it is realized that it would be possible to charge already dry or
dried material
into the furnace space 120. In this case, the initial heating step as
described herein would
not be performed, but the method would skip immediately to the main heating
step
(below).
In one embodiment of the present invention, the provision of hydrogen gas to
the furnace
space 120 during said initial heating step is controlled to be so slow so that
a pressure
equilibrium is substantially maintained throughout the performance of the
initial heating
step, preferably so that a substantially equal pressure prevails throughout
the furnace
space 120 and the not liquid-filled parts of the trough 161 at all times. In
particular, the
supply of hydrogen gas may be controlled so that the said equilibrium gas
pressure does
not increase, or only increases insignificantly, during the initial heating
step. In this case,
the hydrogen gas supply is then controlled to increase the furnace space 120
pressure
over time only after all or substantially all liquid water has evaporated from
the charged
material in the container 140. The point in time when this has occurred may,
for instance,
be determined as a change upwards in slope of a temperature-to-time curve as
measured
by temperature sensor 123 and/or 124, where the change of slope marks a point
at which
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substantially all liquid water has evaporated but the reduction has not yet
started. Alter-
natively, hydrogen gas supply may be controlled so as to increase the pressure
once a
measured temperature in the furnace space 120, as measured by temperature
sensor 123
and/or 124, has exceeded a predetermined limit, which limit may be between 100
C and
150 C, such as between 120 C and 130 C.
In a subsequent main heating step, heat and hydrogen gas is further provided
to the
furnace space 120, in a manner corresponding to the supply during the initial
heating step
described above, so that heated hydrogen gas heats the charged metal material
to a
io temperature high enough in order for metal oxides present in the metal
material to be
reduced, in turn causing water vapour to be formed.
During this main heating step, additional hydrogen gas is hence supplied and
heated,
under a gradual pressure increase inside the furnace space 120, so that the
charged metal
material in turn is heated up to a temperature at which a reduction chemical
reaction is
initiated and maintained.
In the example illustrated in Figures la and lb, the topmost charged material
will hence
be heated first. In the case of iron oxide material, the hydrogen gas will
start reducing the
charged material to form metallic iron at about 350-400 C, forming pyrophytic
iron and
water vapour according to the following formulae:
Fe2O3 + 3H2 = 2Fe + 3H20
Fe30.4 + 4H2 = 2Fe + 4H20
This reaction is endothermal, and is driven by the thermal energy supplied via
the hot
hydrogen gas flowing down from above in the furnace space 120.
Hence, during both the initial heating step and the main heating step, water
vapour is
produced in the charged material. This formed water vapour is continuously
condensed
and collected in a condenser arranged below the charged metal material. In the
example
shown in Figure la, the condenser is in the form of the heat exchanger 160.
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According to the invention, the main heating step, including said condensing,
is performed
until an overpressure has been reached in the furnace space 120 in relation to
atmospher-
ic pressure. The pressure may, for instance, be measured by pressure sensor
123 and/or
5 124. As mentioned above, according to the invention no hydrogen gas is
evacuated from
the furnace space 120 until said overpressure has been reached, and preferably
no hydro-
gen gas is evacuated from the furnace space 120 until the main heating step
has been
completely finalized.
10 More preferably, the supply of hydrogen gas in the main heating step,
and the condensing
of water vapour, is performed until a predetermined overpressure has been
reached in
the furnace space 120, which predetermined overpressure is at least 4 bars,
more prefer-
ably at least 8 bars, or even about 10 bars in absolute terms.
15 Alternatively, the supply of hydrogen gas in the main heating step, and
the condensing of
water vapour, may be performed until a steady state has been reached, in terms
of it no
longer being necessary to provide more hydrogen gas in order to maintain a
reached
steady state gas pressure inside the furnace space 120. This pressure may be
measured in
the corresponding way as described above. Preferably, the steady state gas
pressure may
be at least 4 bars, more preferably at least 8 bars, or even about 10 bars.
This way, a
simple way of knowing when the reduction process has been completed is
achieved.
Alternatively, the supply of hydrogen gas and heat in the main heating step,
and the
condensing of water vapour, may be performed until the charged metal material
to be
reduced has reached a predetermined temperature, which may be at least 600 C,
such as
between 640-680 C, preferably about 660 C. The temperature of the charged
material
may be measured directly, for instance by measuring heat radiation from the
charged
material using as suitable sensor, or indirectly by temperature sensor 123.
In some embodiments, the main heating step, including said condensation of the
formed
water vapour, is performed during a continuous time period of at least 0.25
hours, such as
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at least 0.5 hours, such as at least 1 hour. During this whole time, both the
pressure and
temperature of the furnace space 120 may increase monotonically.
In some embodiments, the main heating step may furthermore be performed
iteratively,
in each iteration the control device 201 allowing a steady state pressure to
be reached
inside the furnace space 120 before supplying an additional amount of hydrogen
gas into
the furnace space. The heat provision may also be iterative (pulsed), or be in
a switched
on state during the entire main heating step.
It is noted that, during the performing of both the initial heating step and
the main heat-
ing steps, and in particular at least during substantially the entire length
of these steps,
there is a net flow downwards of water vapour through the charged metal
material in the
container 140.
During the initial and main heating steps, the compressor 270 is controlled,
by the control
device 201, to, at all times, maintain or increase the pressure by supplying
additional
hydrogen gas. This hydrogen gas is used to compensate for hydrogen consumed in
the
reduction process, and also to gradually increase the pressure to a desired
final pressure.
The formation of water vapour in the charged material increases the gas
pressure locally,
in effect creating a pressure variation between the furnace space 120 and the
trough 161.
As a result, formed water vapour will sink down through the charged material
and con-
dense in the heat exchanger 160, in turn lowering the pressure on the distant
(in relation
to the furnace space 120) side of the heat exchanger 160. These processes thus
create a
downwards net movement of gas through the charge, where newly added hydrogen
gas
compensates for the pressure loss in the furnace space 120.
The thermal content in the gas flowing out from the furnace space 120, and in
particular
the condensing heat of the water vapour, is transferred to the incoming
hydrogen gas in
the heat exchanger 160.
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Hence, this process is maintained as long as there is metal material to reduce
and water
vapour hence is produced, resulting in said downwards gas movement. Once the
produc-
tion of water vapour stops (due to substantially all metal material having
been reduced),
the pressure equalizes throughout the interior of the furnace 100, and the
measured
temperature will be similar throughout the furnace space 120. For instance, a
measured
pressure difference between a point in the gas-filled part of the trough 161
and a point
above the charged material will be less than a predetermined amount, which may
be at
the most 0.1 bars. Additionally or alternatively, a measured temperature
difference
between a point above the charged material and a point below the charged
material but
on the furnace space 120 side of the heat exchanger will be less than a
predetermined
amount, which may be at the most 20 C. Hence, when such pressure and/or
temperature
homogeneity is reached and measured, the main heating step may end by the
hydrogen
gas supply being shut off and the heating element 121 being switched off.
Hence, the main heating step may be performed until a predetermined minimum
temper-
ature and/or pressure has been reached, and/or until a predetermined maximum
temper-
ature difference and/or maximum pressure difference has been reached in the
heated
volume in the furnace 100. Which criterion(s) is/are used depends on the
prerequisites,
such as the design of the furnace 100 and the type of metal material to be
reduced. It is
also possible to use other criteria, such as a predetermined main heating time
or the
finalization of a predetermined heating/hydrogen supply program, which in turn
may be
determined empirically.
In a subsequent cooling step, the hydrogen atmosphere in the furnace space 120
is then
cooled to a temperature of at the most 100 C, preferably about 50 C, and is
thereafter
evacuated from the furnace space 120 and collected.
In the case of a single furnace 100/220, which is not connected to one or
several furnaces,
the charged material may be cooled using the fan 250, which is arranged
downstream of
the gas-water type cooler 240, in turn being arranged to cool the hydrogen gas
(circulated
in a closed loop by the fan 250 in a loop past the valve V12, the heat
exchanger 240, the
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fan 250 and the valve V10, exiting the furnace space 120 via exit conduit 173
and again
entering the furnace space 120 via entry conduit 171). This cooling
circulation is shown by
the arrows in Figure lb.
The heat exchanger 240 hence transfers the thermal energy from the circulated
hydrogen
gas to water (or a different liquid), from where the thermal energy can be put
to use in a
suitable manner, for instance in a district heating system. The closed loop is
achieved by
closing all valves V1-V14 except valves V10 and V12.
Since the hydrogen gas in this case is circulated past the charged material in
the container
140, it absorbs thermal energy from the charged material, providing efficient
cooling of
the charged material while the hydrogen gas is circulated in a closed loop.
In a different example, the thermal energy available from the cooling of the
furnace
100/220 is used to preheat a different furnace 210. This is then achieved by
the control
device 201, as compared to the above described cooling closed loop, closing
the valve V12
and instead opening valves V13, V14. This way, the hot hydrogen gas arriving
from the
furnace 220 is taken to the gas-gas type heat exchanger 230, which is
preferably a coun-
ter-flow heat exchanger, in which hydrogen gas being supplied in an initial or
main heating
step performed in relation to the other furnace 210 is preheated in the heat
exchanger
230. Thereafter, the somewhat cooled hydrogen gas from furnace 220 may be
circulated
past the heat exchanger 240 for further cooling before being reintroduced into
the fur-
nace 220. Again, the hydrogen gas from furnace 220 is circulated in a closed
loop using the
fan 250.
Hence, the cooling of the hydrogen gas in the cooling step may take place via
heat ex-
change with hydrogen gas to be supplied to a different furnace 210 space 120
for per-
forming the initial and main heating steps and the condensation, as described
above, in
relation to said different furnace 210 space 120.
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Once the hydrogen gas is insufficiently hot to heat the hydrogen gas supplied
to furnace
210, the control device 201 again closes valves V13, V14 and reopens valve
V12, so that
the hydrogen gas from furnace 220 is taken directly to heat exchanger 240.
Irrespectively of how its thermal energy is taken care of, the hydrogen gas
from furnace
220 is cooled until it (or, more importantly, the charged material) reaches a
temperature
of below 100 C, in order to avoid reoxidation of the charged material when
later being
exposed to air. The temperature of the charged material can be measured
directly, in a
suitable manner such as the one described above, or indirectly, by measuring
in a suitable
manner the temperature of the hydrogen gas leaving via exit conduit 173.
The cooling of the hydrogen gas may take place while maintaining the
overpressure of the
hydrogen gas, or the pressure of the hydrogen gas may be lowered as a result
of the hot
hydrogen gas being allowed to occupy a larger volume (of the closed loop
conduits and
heat exchangers) once valves V10 and V12 are opened.
In a subsequent step, the hydrogen gas is evacuated from the furnace 220 space
120, and
collected in container 280. This evacuation may be performed by the vacuum
pump 260,
possibly in combination with the compressor 270, whereby the control device
opens
valves V3, V5, V6, V8, V10 and V12, and closes the other valves, and operates
the vacuum
pump 260 and compressor 270 to displace the cooled hydrogen gas to the
container 280
for used hydrogen gas. The evacuation is preferably performed until a pressure
of at the
most 0.5 bars, or even at the most 0.3 bars, is detected inside the furnace
space 120.
Since the furnace space 120 is closed, only the hydrogen gas consumed in the
chemical
reduction reaction has been removed from the system, and the remaining
hydrogen gas is
the one which was necessary to maintain the hydrogen gas / water vapour
balance in the
furnace space 120 during the main heating step. This evacuated hydrogen gas is
fully
useful for a subsequent batch operation of a new charge of metal material to
be reduced.
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In a subsequent step, the furnace space 120 is opened, such as by releasing
the fastening
means 111 and opening the upper part 110. The container 140 is removed and is
replaced
with a container with a new batch of charged metal material to be reduced.
5 In a subsequent step, the removed, reduced material may then be arranged
under an inert
atmosphere, such as a nitrogen atmosphere, in order to avoid reoxidation
during
transport and storage.
For instance, the reduced metal material may be arranged in a flexible or
rigid transport
10 container which is filled with inert gas. Several such flexible or rigid
containers may be
arranged in a transport container, which may then be filled with inert gas in
the space
surrounding the flexible or rigid containers. Thereafter, the reduced metal
material can be
transported safely without running the risk of reoxidation.
15 The following table shows the approximate equilibrium between hydrogen
gas H2 and
water vapour H20 for different temperatures inside the furnace space 120:
Temperature ( C): 400 450 500 550 600
H2 (V01-%): 95 87 82 78 76
20 H20 (V01-%): 5 13 18 22
24
At atmospheric pressure, about 417 m3 hydrogen gas H2 is required to reduce
1000 kg of
Fe2O3, and about 383 m3 hydrogen gas H2 is required to reduce 1000 kg of
Fe304.
The following table shows the amount of hydrogen gas required to reduce 1000
kg of
Fe2O3 and Fe304, respectively, at atmospheric pressure and in an open system
(according
to the prior art), but at different temperatures:
Temperature ( C): 400 450 500 550 600
NM3 H2 / tonne Fe2O3: 8340 3208 2317 1895 1738
NM3 H2 / tonne Fe304: 7660 2946 2128 1741 1596
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The following table shows the amount of hydrogen gas required to reduce 1000
kg of
Fe2O3 and Fe304, respectively, at different pressures and for different
temperatures:
Temperature ( C): 400 450 500 550 600
NM3 H2 / tonne Fe2O3:
1 bar 8340 3208 2317 1895 1738
2 bars 4170 1604 1158 948 869
3 bars 2780 1069 772 632 579
4 bars 2085 802 579 474 434
5 bars 1668 642 463 379 348
6 bars 1390 535 386 316 290
NM3 H2 / tonne Fe304:
1 bar 7660 2946 2128 1741 1596
2 bars 3830 1473 1064 870 798
3 bars 2553 982 709 580 532
4 bars 1915 737 532 435 399
5 bars 1532 589 426 348 319
6 bars 1277 491 355 290 266
As described above, the main heating step according to the present invention
is preferably
performed up to a high pressure and a high temperature. During the majority of
the main
heating step, it has been found advantageous to use a combination of a heated
hydrogen
gas temperature of at least 500 C and a furnace space 120 pressure of at least
5 bars.
Above, preferred embodiments have been described. However, it is apparent to
the
skilled person that many modifications can be made to the disclosed
embodiments
without departing from the basic idea of the invention.
For instance, the geometry of the furnace 100 may differ, depending on the
detailed
prerequisites.
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The heat exchanger 160 is described as a tube heat exchanger. Even if this has
been found
to be particularly advantageous, it is realized that other types of gas-gas
heat exchang-
ers/condensers are possible. Heat exchanger 240 may be of any suitable
configuration.
The surplus heat from the cooled hydrogen gas may also be used in other
processes
requiring thermal energy.
The metal material to be reduced has been described as iron oxides. However,
the present
method and system can also be used to reduce metal material such as the above
men-
tioned metal oxides, such as of Zn and Pb, that evaporate at temperatures
below about
600 C.
The present direct reduction principles can also be used with metal materials
having
higher reduction temperatures than iron ore, with suitable adjustments to the
construc-
tion of the furnace 100, such as with respect to used construction materials.
Hence, the invention is not limited to the described embodiments, but can be
varied
within the scope of the enclosed claims.
